MODEL ESP-D SYSTEM INSTALLATION, OPERATION & MAINTENANCE MANUAL

Transcription

1 ESPD MODEL ESP-D SYSTEM INSTALLATION, OPERATION & MAINTENANCE MANUAL Central Air Conditioning Series 2 to 5 Tons Fan Coil Unit/Air Supply Components SECTION 1: INTRODUCTION Space-Pak System Design... Code Compliance... Air Distribution Requirements... Air Distribution Components... Warranty Information... Shipment of Unit... SECTION 2: SYSTEM INSTALLATION Step 1: Locating The Unit... 6 Step 2: Cutting Return Air Opening... 8 Step 3: Attaching Supply Air Plenum Ring... 9 Step 4: Setting The Unit Step 5: Installing The Condensate Trap & Line Step 6: Wiring The Unit... Step 7: Installing Air Distribution Components... SECTION 3: START UP & OPERATION Sequence Of Operation Prior To Start-Up System Start-Up & Adjustements Charging Cooling Only Systems SECTION 4: MAINTENANCE Before Each Cooling Season... If System Fails To Operate... Parts List IN UNITED STATES: 260 NORTH ELM ST. WESTFIELD, MA (413) /FAX (413) IN CANADA: 5211 CREEKBANK ROAD, MISSISSAUGA, ONTARIO, L4W 1R3 (905) /FAX (905)

2 Section 1: INTRODUCTION The following terms are used throughout this manual to bring attention to the presence of potential hazards or to important information concerning the product: DANGER: Indicates an imminently hazardous situation which, if not avoided, will result in death, serious injury or substantial property damage. WARNING: Indicates a potentially hazardous situation which, if not avoided, could result in death, serious injury or substantial property damage. CAUTION: Indicates a potentially hazardous situation which, if not avoided, may result in minor injury or property damage. NOTICE: Used to notify of special instructions on installation, operation or maintenance which are important to equipment but not related to personal injury hazards. SPACE-PAK SYSTEM DESIGN Space-Pak is a hi-velocity central air conditioning system which utilizes a conventional outdoor condensing unit matched with the indoor Model ESP-D fan coil unit to provided conditioned air through the specially-designed, pre-fabricated, pre-insulated flexible duct system. The system and its basic components operate the same as in any conventional air-to-air cooling system. The Space-Pak system is covered by the following U.S. Patents: 3,507,354; 3,575,234; 3,596,936; 3,605,797; 3,685,329; 4,045,977; 4,698,982; 926,673 and Canadian Patents: 891,292; 923,935; 923,936. CODE COMPLIANCE Fan coil unit installation must conform to the requirements of the local authority having jurisdiction or, in the absence of such requirements, to the National Board of Fire Underwriters regulations. Fan coil unit meets ETL listing requirements. All electrical wiring must be in accordance with the National Electrical Code ANSI/NFPA No. 70-latest edition and any additional state or local code requirements. If an external electrical source is utilized, the fan coil unit, when installed, must be electrically grounded. AIR DISTRIBUTION SYSTEM COMPONENT REQUIREMENTS Air distribution components installation must conform to the requirements of local authority having jurisdiction or, in the absence of such requirements, to the National Board of Fire Underwriters Code 90A or 90B. Do not begin the installation of the system without a system layout and material take-off. If a layout plan is not already available and room terminator requirements determined, then refer to the Space-Pak Application Manual, SP9, to complete this information. A description of air distribution system components is shown in Figure

3 TEE CAP ORIFICE DUCT FAN COIL UNIT RIGID 90 ELBOW RETURN AIR DUCT SOUND ATTENUATING TUBING TERMINATOR PLATES KWIK CONNECTS TAKEOFF RETURN AIR BOX CLAMP BAND RETURN AIR BOX (SPC-1D, 2D, & 3D): Each includes filter grill with metal frame, permanent 14" x 25" x 1" (1D, 2D), 14" x 36" x 1" (3D) filter, and 2 clamp bands. SPC-1D is for ESP-2430D. SPC-2D is for ESP-3642D and SPC-3D is for ESP-4860D. RETURN AIR DUCT (SPC-4,5, & 6): Flexible, 6 feet long with round shape. SPC-4 (15" dia.) for ESP-2430D. SPC-5 (19" dia.) for ESP-3642D and SPC-6 (24" dia.) is for ESP-4860D. DUCT (SPC-13-8): Rigid, 9" I.D., 11" O.D. fiberglass with aluminum vapor barrier. Each section is 6 feet long. TEE (SPC-14-4A): Same construction as duct. ELBOW (SPC-19-4): Same construction as duct. 14" Radius. Rigid 90. INSTALLATION KIT COMPONENTS (SPC-50-5A) S.A. tubing w/ kwik-connects installed (5) Kwik-connects (10). Plenum Take-offs (5). clips and gaskets. 2 ea. 15%, 35% and 50% balancing orifices END CAP (SPC-16-10): Insulated metal cap. SUPPLY TUBING (SPC ): Flexible, insulated, 2" I.D. and 3 1 4" O.D. Each section is 100 feet long. INSTALLATION KIT (SPC-50-2A & 5A): Each contains appropriate amount of sound attenuating (S.A.) tubing sections, kwik-connects, plenum take-offs, terminator plates and balancing orifices to complete 2 (SPC-50-2A) or 5 (SPC-50-5A) room outlets. ADDITIONAL COMPONENTS (not shown) WINTER SUPPLY SHUT OFF (SPC-42-10): To keep moisture from collecting in ductwork during winter months. Terminator plates (5) with clips and screws HOLE CUTTER (SPC-71-10): To cut 2" hole in plenum for plenum take-off installation. PLIERS (SPC-72): To assure full setting of all clips (fasteners) in plenum take-off. FIGURE 1.1: AIR DISTRIBUTION SYSTEM COMPONENTS 3

4 Plenum Duct The plenum duct can be run in practically any location accessible for the attachment of the supply tubing (see suggested layouts in Figure 1.2). The plenum is normally located in the attic or basement, and it is usually more economical to run the plenum where it will appreciably shorten the lengths of two or more supply runs. In some two-story split level homes, it may be advantageous to go from one level to another with the plenum duct. Whenever necessary, either between floors or along the ceiling, the small size of the plenum makes it easy to box in. The blower coil unit is designed to operate with a total external static pressure of 1.5 inches of water column (minimum maximum 1.5). Excessive static pressure increases the air flow in individual runs and may cause some or all terminators to be noisy. For systems with a tee installed as on Unit No. 1 (Figure 1.3), the best results are obtained if not more than 60% of the total number of system outlets are attached to any one branch of the tee. For systems with a tee installed as on Unit No. 2 (Figure1.3), not more than 30% of the total number of system outlets should be attached to the perpendicular branch of the tee. FAN COIL UNIT FAN COIL UNIT FAN COIL UNIT FOR ESP ONLY FAN COIL UNIT FIGURE 1.2: /TUBING LAYOUT EXAMPLES (FOR GUIDANCE ONLY) 4

5 UNIT NO. 1 FAN COIL UNIT MINIMUM 18" NO MORE THAN 60% OF CAPACITY ON ONE SIDE ROOM TERMINATOR UNIT NO. 2 FIGURE 1.4: TERMINATOR IN SOFFIT AREA FAN COIL UNIT MINIMUM 18" 30% MAX. OF CAPACITY ROOM TERMINATOR SUPPLY TUBING FIGURE 1.3: ESP-4860D INSTALLATION The larger system capacities (ESP-4860D) are effected more by higher system static pressure than the smaller systems. The four and five ton system should be considered and handled as two separate smaller units. Installation of the plenum tee closer than the minimum indicated in Fig. 1.3 will reduce performance of the system. No supply runs should be installed between unit outlet and this tee. Static readings on system should be taken before tee. Supply Tubing In the case of two-story or split-level applications, supply tubing may run from one story to another. It is small enough to go in stud spaces, but this is often difficult in older homes because of hidden obstructions in stud spaces. It is more common to run the supply tubing from the attic down through second story closets to the first story terminators. Supply tubing runs in the corners of the second story rooms can be boxed in and are hardly noticeable since overall diameter is only 3 1 4". Room Terminators Terminators should be located only in the ceiling or floor for vertical discharge. Horizontal discharge is acceptable, but is sometimes more difficult to install. Two excellent spots for horizontal discharge are in the soffit area above kitchen cabinets (see Figure 1.4) and in the top portion of closets (see Figure 1.5). 5 FIGURE 1.5: TERMINATOR IN CLOSET TOP AREA Terminators should always be out of normal traffic patterns to prevent discharge air from blowing directly on occupants. And they should not be located directly above shelves or large pieces of furniture. Outside wall or corner locations are recommended if the room has more than one outside wall. Locating terminators away from interior doors prevents short cycling of air to the return air box. WARRANTY INFORMATION Refer to the Limited Warranty published on the back page of this manual. SHIPMENT OF UNIT Each fan coil unit is shipped in a single carton. Packed with the unit, there is a supply air plenum flange with gasket, vibration isolation pads, a condensate trap assembly and a length of 6" wide foil faced fiberglass insulation.

6 SECTION 2: SYSTEM INSTALLATION NOTICE: Before proceeding with the installation, we recommend reading through this section of the manual for an overall understanding of the air conditioning fan coil unit and air distribution system component installation procedures. STEP 1: LOCATING THE UNIT The fan coil unit may be installed in an unconditioned space (as long as it is protected from the weather) such as an attic, garage or crawlspace...or a conditioned space such as a basement, closet or utility room (see dimensions in Figure 2.2 and 2.3). The fan coil unit is shipped in a horizontal air flow arrangement, but can be easily field-converted to a vertical air flow arrangement (see Figures 2.8 and 2.9). When selecting a location, consider the locations as shown in Figures 2.4, 2.5 and 2.6 of the return air box; routing of the plenum duct, supply tubing, refrigerant lines, condensate drain line; and all recommended clearances (see Figures 2.2 and 2.3). When installing unit in an attic (above a room ceiling), recommend installing a secondary drain pan or optional float switch. Follow local code requirements. Model System capacity (Nom. Tons) Electrical Characteristics Suction Line Liquid Line Connections Cond. Drain (NPT) Return Inlet (Dia.) Supply Outlet (I.D.) Recommended Condensing Unit Capacity (MBH) Min SEER ESP-2430D ESP-3642D ESP-4860D 2-2-1/ /2 4 & / / /230 7/8" 7/8" 7/8" 3/8" 3/8" 3/8" 3/4" 3/4" 3/4" 15" 19" 24" 9" 9" 9" 24 to to to Blower Coil Model System capacity (Nom. Tons) Std. 1.5" W.C. Wheel Dia. and Width Motor HP Motor Type F.L. Amps No. of Rows Deep Refrig. Charge (R-22) Flow Control Type Ship. Wt. (lbs) ESP-2430D ESP-3642D ESP-4860D 2-2-1/ /2 4 & " x 5" 9" x 5" 9" x 6-3/8" 1/3 1/2 3/4 PSC PSC PSC FIGURE 2.1: MODEL ESP-D SPECIFICATIONS 0 Exp. Valve 0 Exp. Valve 0 Exp. Valve MODEL A B C ESP-2430D 24-1/8" 12" 16-7/8" ESP-3642D 33-1/8" 16-1/2" 24-1/4" ESP-4860D 43-1/8" 21-1/2" 34-1/8" D 15-3/8" 16-1/2" 21-1/2" 10-7/8" I.D. SUPPLY 7/8" SWEAT (SUCTION) 3/8" SWEAT (LIQUID) 38" MIN. CLEARANCE 1-5/8" 8" MIN. CLEARANCE 12" MIN. CLEARANCE C 5-1/2" ELECTRICAL CONTROL BOX 2-1/2" 3-1/2" 6" 7" RETURN 11-5/16" 14" 1-5/8" 28-1/2" 30" 1" B 3/4" N.P.T. DRAIN CONN. FIGURE 2.2: HORIZONTAL AIR FLOW UNIT DIMENSIONS AND CLEARANCES D A 6

7 MODEL A B C D ESP-2430D 24-1/8" 12" 16-7/8" 15-3/8" ESP-3642D 33-1/8" 16-1/2" 24-1/4" ESP-4860D 43-1/8" 21-1/2" 34-1/8" 16-1/2" 21-1/2" 5-1/2" 10-7/8" I.D. 7/8" SWEAT (SUCTION) SUPPLY 3/8" SWEAT (LIQUID) 8" MIN. CLEARANCE 38" MIN. CLEARANCE 1-5/8" D 12" MIN. CLEARANCE 1-5/8" ELECTRICAL CONTROL BOX 3-1/2" 6" 7" RETURN 11-5/16" 14" C 28-1/2" 1" B 30" 3/4" N.P.T. DRAIN CONN. A FIGURE 2.3: VERTICAL AIR FLOW UNIT DIMENSIONS AND CLEARANCES CLAMP BAND SUPPLY AIR OUTLET (ALTERNATE LOCATION) FLEXIBLE RETURN DUCT (90 BEND) CLAMP BAND SPACE-PAK FAN COIL UNIT 48" SUPPLY AIR OUTLET RETURN AIR BOX WITH GRILL & FILTER PLATFORM (FIELD ERECTED AS SHOWN IN STEP 4) FIGURE 2.4: TYPICAL UNIT INSTALLATION SUPPORT RETURN AIR BOX Ft. MAXIMUM FLEXIBLE RETURN DUCT 2 Ft. SUPPORT MAX. 90 FAN COIL UNIT PLATFORM (FIELD ERECTED AS SHOWN IN STEP 4) FIGURE 2.5: HORIZONTAL AIR FLOW UNIT INSTALLATION 7

8 SUPPORT RETURN AIR BOX Ft. MAXIMUM FLEXIBLE RETURN DUCT 2 Ft. SUPPLY SUPPORT MAX. AIR FAN COIL UNIT 90 PLATFORM (FIELD ERECTED AS SHOWN IN STEP 4) FIGURE 2.6: VERTICAL AIR FLOW UNIT INSTALLATION STEP 2: CUTTING RETURN AIR OPENING Select exact location for return air box. Avoid installing box in dining room, living room, kitchen, etc., unless return air duct can be installed with 180 bend (accomplished by splicing two return air ducts together.) For all wall return applications, cut the return air opening to accomodate the return air box according to the same dimensions. Remember, location of opening must allow for a 90 bend in the return air duct. For attic installations to raise fan coil unit up through opening, cut return air opening 14 1 /2" wide by 27" long for the ESP-2430D and the ESP-3642D and 14 1 /2" wide by 37 long for the ESP-4860D. These openings will accomodate the return air box with sufficient frame lip to cover the opening (see Figure 2.7). Check the opening for proper fit of the return air box. Do not install the return air box until the installation of the entire Space-Pak system is completed, if you want to fit materials up through this hole. If joists are on 16" centers, the 14 1 /2" width of the return air box should fit between successive joists. Where joists run in the opposite direction, or to properly center the return, it may be necessary to cut joists and install headers. A 1/2" 4" MODEL A B SPC-1D SPC-2D 25" 36-3/8" 28" 38-9/16" SPC-3D 36-3/8" 38-9/16" LOUVERS HINGED PANEL B 16-1/2" 14-5/16" FIGURE 2.7: RETURN AIR BOX FRAME DIMENSIONS 8

9 STEP 3: ATTACHING SUPPLY AIR RING NOTE: If the unit is to be located in the attic and installed through the ceiling joists, attach the supply plenum flange in the attic. A. HORIZONTAL DISCHARGE: Refer to Figure 2.8. B. VERTICAL DISCHARGE: Refer to Figure 2.9A & 2.9B Tools required: 5 /16" box wrench, 5 /16" nut driver, drill and 1 /4" drill bit. Refer to Figure 2.9A for Steps 2 to 5a. 1. Place unit horizontally on a flat surface. 2. Remove side access panels, the cover plate from the top panel and top of unit. 3. Remove the two screws securing the front panel flange to the blower housing. 4. Remove the two screws attaching the blower housing to the motor support channel flange. 5a. Remove the six (6) screws attaching the motor mounting base to the motor support channel. Refer to Figure 2.9B for Steps 5b to 14. 5b. Shift the motor mounting base (and blower housing) back towards the coil to the second set of mounting lugs on the motor support channel. When in position, reattach the motor mounting base to the motor support channel with the six screws. 6. Rotate the blower housing 90 to face upwards. Align the hole in the side blower housing with the upper slot in the motor support channel flange and join the two parts with one of the previously removed screws. 7. Attach the two flanges supplied, one to each side of the blower housing outlet. Align the holes in the flange with the holes in the housing and attach with screws supplied. 8. Drill out the four (4) screw holes in the top panel securing the removed cover plate to 1 4 " inch diameter. 9. Make a 2" long cut in the top panel insulation from each corner of the opening toward the sides of the unit to prepare for Step Reposition the top panel on the unit taking care to straddle the evaporator coil with coil support brackets and to replace all screws. 11. Fold back the top insulation flaps created in Step 9 and position the flanges on the blower housing discharge against the top panel. Place the supply plenum flange over the opening. Align the holes in the flange, gasket and top panel with the blower housing flange holes and secure with the screws provided. Reposition the top insulation flaps over the blower housing flanges. The insulation must be in place to prevent condensation forming on the top panel. 12. Check that the blower wheel is centered in the inlet and discharge of the blower housing. To make any adjustments, loosen the 4 bolts securing the motor, shift the motor as required and refasten the 4 bolts. 13. Place the coverplate removed from the top panel over opening in the front panel and screw in place. NOTE: Check that all inside cabinet surfaces are covered with insulation, add insulation if required. An uninsulated panel will sweat and condensate will form on the cabinet. 14. Replace the side access panels. 9

10 SUPPLY AIR FLANGE MOUNTING SCREWS (4 SUPPLIED) GASKET FIGURE FIGURE 2.9A 4 5a FIGURE 2.9B b 14 10

11 STEP 4: SETTING THE UNIT Construct a platform for the fan coil unit, as shown in Figure The platform can be constructed of 2x4 (minimum), 2x6, 2x8 and 2x10 lumber, as necessary to achieve proper pitch of 1 4" per foot for the condensate drain line. Figure 2.11 shows the approximate normal allowable run of condensate piping as a function of the framing lumber used for platform construction. The platform covering should be 1 2" plywood minimum. Attach vibration isolation pads (supplied with fan coil unit) to platform covering as shown in Fig Secure the platform to the joist or floor, depending on location selected for the fan coil unit. Make sure platform is level. For locations where the fan coil unit will be suspended, suspend platform from overhead by 1 4" threaded rods. NOTICE: Leave room on sides for servicing. For installations with a return air box and return air duct, set fan coil unit on the platform with the elliptical opening facing in the direction of the return air opening. The supply air plenum flange should overhang the platform. DO NOT let the flange support the weight of the unit. Do not secure the unit to the platform, as the weight of the unit will hold it in position. STEP 5: CONNECTING REFRIGERANT LINES Connect refrigerant lines from the outdoor condensing unit to the fan coil unit in accordance with its manufacturer's sizing recommendations for the length of the piping run. Proper line sizing is critical to the operation of the system. Always use proper brazing procedures. A trickle flow (2PSI) of dry nitrogen to avoid scale or blockage in the piping system is recommended while brazing. Spacepak also recommends installing a sight glass on the liquid line outside of the unit as an aid for accurately charging the system. LUMBER SIZE 2 X 4 2 X 6 2 X 8 2 X 10 MAXIMUM HORIZONTAL 8' 16' 24' 32' FIGURE 2.11: CONDENSATE PIPING RUNS 4 STRIPS 4" x 30" x 1" THICK POLYURETHANE FOAM FOR MODEL ESP-2430D 30" AIR FLOW 25" 1 STRIP 4" x 15" x 1" THICK POLYURETHANE FOAM 1 STRIP 4" x 9" x 1" THICK POLYURETHANE FOAM 30" 34" AIR FLOW 1 STRIP 4" x 15" x 1" THICK POLYURETHANE FOAM 5 STRIPS 4" x 30" x 1" THICK POLYURETHANE FOAM FOR MODEL ESP-3642D 1 STRIP 4" x 14" x 1" THICK POLYURETHANE FOAM 30" AIR FLOW 44" 1 STRIP 4" x 15" x 1" THICK POLYURETHANE FOAM 7 STRIPS 4" x 30" x 1" THICK POLYURETHANE FOAM FOR MODEL ESP-4860D 1 STRIP 4" x 16" x 1" THICK POLYURETHANE FOAM FIGURE 2.10: MOUNTING PLATFORMS 11

12 BN BLK STEP 6: INSTALLING THE CONDENSATE TRAP & LINE Refer to Fig. 2.2 & 2.3 for condensate drain location. All components for the PVC condensate trap are provided in a separate bag with fan coil unit (see Fig. 2.12) and should be cemented together with PVC pipe cement. NOTICE: Never connect condensate line to a closed drain system. When installing unit in an attic (above a room ceiling), recommend installing a secondary drain pan or optional float switch. CAUTION: Do not use substitute trap. Do not cut off or alter trap components. Screw male adapter (see Fig. 2.12) into unit condensate line connection. Assemble and cement remaining components together. Then cement assembly to male adapter. The 45 elbow provides an offset from beneath unit suction line for assess to clean-out plug. Run a condensate line from the trap to a suitable drain that s in accordance with local codes. Make sure the line is pitched 1 4" per foot. PIPE PLUG CLEAN-OUT TEE CONDENSATE TRAP TUBE TO DRAIN 2-1/4" BUSHING (WHITE) 45 ELBOW SLIP JOINT 5-3/8" MALE ADAPTER SLIP JOINT 45 ELBOW MALE ADAPTER FIGURE 2.12: CONDENSATE TRAP ASSEMBLY STEP 7: WIRING THE UNIT DANGER: Turn off electrical power supply before servicing. Contact with live electric components can cause shock or death. installed in accordance All electrical and control wiring must be installed in accordance with the codes listed in Section 1 of this manual. Wiring diagram is provided in Figure A separate 208/230/60/1 power supply is recommended for the unit. Use standard 15-amp fuse and 14-gauge wire from power supply to unit. The low voltage transformer in the unit has a 208 volt tap in the primary winding (color coded RED). If unit is to be operated with 208 volt electrical service, remove the 230 volt ORANGE lead from the L2 terminal and connect the 208 volt RED lead to the L2 terminal. Be sure to insulate the end of the unused ORANGE lead. Locate the room thermostat on a wall near the return air box, between 40" to 48" from the floor. Connect the lowvoltage thermostat wiring from the room thermostat to the low voltage control block in the unit. Connect power supply to Terminals L1 (hot) and L2 (hot) on the high voltage terminal block. Connect a ground wire to the equipment ground terminal located next to the high voltage terminal block. SUPPLY VOLTAGE 208/230/60/1 L1 L2 H.VOLTAGE T.BLOCK BLK BLK 5 4 WHT FR1 ORG 208V INPUT WHT FAN CAPACITOR FAN MOTOR FR AFS FIELD NEC CL-1 FIELD NEC CL-2 FACTORY NEC. CL-1 FACTORY NEC. CL FAN RELAY ANTI-FROST SWITCH RD FS FLOAT SWITCH (OPTIONAL) OUTDOOR UNIT R G Y EQUIP. GRD. L. VOLTAGE T. BLOCK YEL YEL BLK BLU YEL 24V OUTPUT FR CONTROL BOX TRANSFORMER BLU 3 1 FR2 BRN BRN GRD. LEAD TO MOTOR BASE AFS FS G R Y NOTES COOL T'STAT TERM. 1. FAN MOTOR FURNISHED WITH INHERENT THERMAL PROTECTION 2. TO BE WIRED IN ACCORDANCE WITH NATIONAL ELECTRIC CODES (NEC) AND LOCAL CODES. 3. USE COPPER CONDUCTORS ONLY. 4. TRANSFORMER IS WIRED FOR 230V SUPPLY. IF 208V IS USED CHANGE TRANSFORMER PRIMARY WIRING. FIGURE 2.13: MODEL ESP-D WIRING SCHEMATIC 12

13 STEP 8: INSTALLING AIR DISTRIBUTION COMPONENTS All plenum duct and supply tubing runs as well as room terminator locations must be in accordance with air distribution system requirements listed in Section 1 of this manual. Where taping of joints is required, recommend Polyken # 222 tape or equivalent. PREPARING Plenum Duct Installation All tees, elbows and branch runs must be a minimum of 18 from the fan coil unit or any other tee, elbow or branch run. Keep all tees and elbows to a minimum to keep system pressure drop on larger layouts to a minimum. Plenum duct comes in 6-foot sections and may be cut to length. Begin installing plenum duct (see Figure 2.14). For straight or branched plenum run cut off the female end of a plenum duct section. In the case of a bull head tee (see Unit No. 1 in Figure 1.3 on page 5) cut off the male end of a plenum duct section.then insert duct into fan coil unit receiving collar. Push duct in tight to form snug joint, flatten the sheet metal tabs against the duct and insert flat head pins. Remove paper backing on rectangular foam pieces and place over pins head. Tape the unit/plenum joint securely. To prevent air leakage and condensation, wrap and tape in place the 6" wide piece of foil faced fiberglass insulation over the taped joint. Be sure insulation is pushed up against the unit. Continue to assemble plenum duct, making sure shiplap joints (see Figure 2.15) are snug and taped securely. Remember, for the ESP-4860D system, a plenum tee must be installed 18" minimum from the fan coil unit before continuing plenum duct run (see air distribution system requirements in Section 1 of this manual). REMOVE FLANGE TAB TAB INSERTING TAPED JOINT INSULATED JOINT FIGURE 2.14: INSTALLATION AT UNIT FIGURE 2.15: SHIP-LAP JOINT Plenum tee and elbow fittings may be installed at any point in the plenum duct run. If installing a fitting at the end of a full plenum section (see Figure 2.16), insert female end of fitting into duct. If installing a fitting at a cut in the plenum duct (see Figure 2.16), form a fieldfabricated flange (1 1 2" wide) in the duct and insert male end of fitting into duct. Tape the joint securely. An end cap must be installed at the end of each duct run. The cap contains an insulating cushion which is pushed up tight against the duct end. (If installing end cap at the end of a full plenum section, remove shiplap joint first). Holding cap firmly in place (see Figure 2.17), insert flat head pins through the sheet metal tabs on the end cap. Remove paper backing on rectangular foam pieces and place over pin heads. Cross-tape cap to the plenum duct, and then tape it circumferentially to the plenum duct. AT END OF FULL SECTION FORM FLANGE WHERE DUCT IS CUT FIGURE 2.16: FITTING INSTALLATION 13

14 4" DIA. SHEET METAL TABS END CAP 5" 5" FIGURE 2.19: TERMINATOR MEASUREMENTS X-TAPE CAP TO DUCT FIGURE 2.17: END CAP INSTALLATION Room Terminator & Sound Attenuating Tubing Installation Room terminators and pre-assembled sound attenuating tubing are provided in the Installation Kits. NOTICE: Do not install terminators in a wall in which a sharp bend in the sound attenuating tubing is required (see Figure 2.18). The result would be unacceptable noise. DRY WALL OR PLASTER TERMINATOR SOUND ATTENUATING TUBING THIS RADIUS TOO SHORT STUD SPACE FIGURE 2.18: INCORRECT TUBING INSTALLATION In marking location for room terminator (see Figure 2.19), the center of the terminator should be 5" from the wall or, when installed in the corner of a room 5" from both walls. After marking location, drill a 1 8" diameter hole for outlet to be sure there is at least a 2" clearance all around the 1 8" hole to receive tubing and connector. Adjust direction of hole as needed, to gain this 2" clearance. After all clearances have been checked, take a 4" diameter rotary-type hole saw and cut a hole, using the 1 8" diameter hole as a pilot. 14 Assemble the room terminator to the sound attenuating tubing by simply fitting the two pieces together and twisting until tight (see Figure 2.20). If the terminator is to be used in a floor location, then field fabricate a small screen (1 1 2" square; 1 4 x gauge galvanized wire screen) and place screen over opening on the back of the terminator prior to twisting on the kwik-connect (on the sound attenuating tubing). NOTICE: Do not shorten sound attenuating tubing length. The result would be unacceptable noise. Push the free end of the sound attenuating tubing through the 4" hole until the two toggle springs on the room terminator snap into place. Center the two spring clips on a line parallel to the direction of the tubing routing from the room terminator (see Figure 2.20). This is important since the weight of the tubing will have a tendency to cause a part of the terminator to pull away from the ceiling if the clips and tubing do not run parallel. Then tighten the screws (attached to the terminator) until the terminator is snug against the ceiling or floor. Do not overtighten. For installations with floors or ceilings which are thicker than normal, longer toggle screws or special mounting plates may be required. TUBING ROUTING FIGURE 2.20: POSITIONING ROOM TERMINATOR Supply Tubing Installation Kwik-connects, plenum take-off gaskets, plenum takeoffs and balancing orifices are provided in the Installation Kits. Avoid sharp bends in the supply tubing (as well as the sound attenuating tubing). The minimum radius bend is 4" (see Figure 2.21); however, wherever possible, hold to a larger radius.

15 At the plenum in the location selected for attaching the supply tubing, cut a 2" diameter hole in the plenum with the Space-Pak plenum hole cutter (see Figure 2.24). 4" MINIMUM RADIUS FIGURE 2.21: MINIMUM TUBING BEND At the plenum, all supply tubing connections must be a minimum of 18" from any plenum tee, plenum elbow, the fan coil unit or another supply tubing connection. Individual supply tubing runs must be a minimum of 6-feet, even if the distance between the sound attenuating tubing and plenum is less than 6 feet. Supply tubing comes in 100-foot sections and may be cut to length with a knife or fine tooth hacksaw. For each supply tubing run, estimate and cut the length of tubing that will be needed between the plenum and sound attenuating tubing. At the open end of the supply tubing which will attach to the sound attenuating tubing, install a kwik-connect (see Figure 2.22). First, push back the cover and the insulation exposing the inner core. Second, twist a kwik-connect into the inner core. Third, pull down the insulation and cover, and tuck it into the deep groove on the back of the kwik-connect. Fourth, wrap the connection securely with tape. This hole should be cut on the side approximately at a 20 downward angle to eliminate strain on the plenum take-off when tubing is attached. Rotate the cutter as pressure is applied to force the serrated edge through the aluminum foil and insulation. Remove the hole cut-out from the plenum. Make sure there is no flap left inside plenum that could block hole during operation. 20 FIGURE 2.24: CUTTING HOLE IN Place the plenum take-off gasket on the back side of the plenum take-off and insert the assembly into the hole in the plenum (see FIgure 2.25). NOTICE: Gasket must be installed to seal plenum take-off to prevent air leakage. FIGURE 2.22: KWIK-CONNECT INSTALLATION When finished, simply twist together (see Figure 2.23) the kwik-connect on the sound attenuating tubing, and wrap the connection securely with tape. After attaching the supply tubing to the sound attenuating tubing, bring the open end of the tubing to the plenum. GASKET FIGURE 2.25: TAKE-OFF INSTALLATION Orient the plenum take-off to match the curvature of the plenum duct. Hand insert the four plenum take off fasteners one at a time and using the Space-Pak pliers, snap the fasteners into place until they lock in place (see Figure 2.26). FIGURE 2.23: CONNECTING TUBING NOTICE: All four fasteners must be installed to assure air tight fitting between plenum take-off and plenum. 15

16 GASKET TAKE-OFF GASKET TAKE-OFF FASTENER FASTENER 1. HAND INSERT FASTENER INTO TAKE-OFF 2. WITH PLIERS, SNAP FASTENER INTO PLACE UNTIL IT LOCKS IN PLACE FIGURE 2.26: TAKE-OFF FASTERNER INSTALLATION In accordance with your calculations as to requirements for balancing orifices, mount the orifice in the outlet of the plenum take-off (see Figure 2.27), prior to attaching the supply tubing. Next, install a kwik-connect in the open end of the supply tubing, using the same procedures as before, and twist together kwik-connects on supply tubing and plenum take-off. Wrap connection securely with tape. Remove the grill and the filter from the grill frame. Insert the frame into the box and mount in place with the screws provided through a hole at each corner of the frame. Finally, place the air filter into the frame and replace the grill. Turn the latches a quarter turn to lock the grill in place. Slide a clamp band (provided with return air box) over one end of the return air duct. Place that end over the elliptical flange on the fan coil unit (see Figure 2.29). Move the clamp over the flange and tighten so the clamp holds the return air duct securely to the flange. Follow the same procedures to attach the return air duct to the return air box (see Figure 2.29). FIGURE 2.27: ORIFICE INSTALLATION Return Air Box & Duct Installation Remove the return air grill from the return air box and remove the air filter from the return air grill. Insert the return box from below for ceiling installation (or from the front for wall installations) and fasten with four screws through holes provided on the long side of the box. (see Figure 2.28). RETURN AIR BOX RETURN AIR FILTER GRILL FIGURE 2.29: RETURN AIR DUCT INSTALLATION Winter Supply Shut-Off Installation Simply snap winter supply shut-offs into the room terminator openings (see Figure 2.30). Wrap the return air filter in a plastic bag and reinstall it to block the return air opening. Winter supply shut-offs prevent moisture from collecting in ductwork during winter months. Be sure to remove the plastic bag and all supply shut-offs before operating the system. WINTER SUPPLY SHUT-OFF ROOM TERMINATOR FIGURE 2.28: RETURN AIR BOX INSTALLATION FIGURE 2.30: WINTER SUPPLY SHUT-OFF 16

17 SECTION 3: START-UP & OPERATION SEQUENCE OF OPERATION When power is turned on and thermostat fan switch is set to ON and the cooling indicator is set to OFF, the indoor fan motor is energized through the normally open contact FR1 of the FR fan relay in about 30 seconds. The outdoor unit is off. When power is turned on and thermostat fan switch is set to ON or AUTO and the cooling indicator to COOL the indoor and outdoor units will start through the normally open contacts FR1 and FR2 of the FR fan relay. AUTO position on the thermostat will stop and start your system when the temperature setting is satisfied. The ON position on the thermostat will stop the outdoor unit only when the temperature setting is satisfied and the indoor unit will continue to run, recirculating indoor air. The fan coil unit is equipped with a protective device called an anti-frost control which will automatically stop the outdoor unit (while the indoor unit continues to run) if ice accumulates on the indoor unit evaporator coil causing abnormal operating conditions. When the accumulated ice has melted, the anti-frost control will restart the outdoor unit. If fan coil unit is equipped with an optional float switch, the condensing unit will automatically shut down if the drain pan is full of water (condensate) and not draining. The fan coil unit will continue to operate. When the water level in the drain pan drops, the system will continue normal operation. PRIOR TO START-UP 1. Check all electrical connections for tightness. 2. Check air filter has been installed in return air box or filter box. 3. Remove all winter supply shut-offs and store them in a safe place. STEP 9: INITIAL SYSTEM START UP & OPERATION 1. Place thermostat fan switch in ON position and cooling indicator in OFF position. In about 30 seconds, indoor unit blower will start. 2. Check blower operation for excess noise or vibration. 3. Check entire distribution system for leakage and apply additional tape where necessary. 4. Check that system static pressure is within acceptable limits (minimum 1.0" W.C. - maximum 1.5" W.C.). Static readings must be taken in the plenum a minimum of 18" (or after the tee on ESP-4860D systems) from the fan coil unit, plenum tees or elbows but before any supply run. 5. Check that blower motor amp draw compares with fan coil unit rating plate. Amp draw shown on plate is the FLA of motor (not the actual running amps) and will vary with the pressure and voltage. 6. Place the thermostat cooling indicator in COOL position, which will start the outdoor unit. Let the system run at least 30 minutes to stabilize operating conditions. 7. For outdoor unit start-up, follow manufacturer s instructions. 8. Check that temperature drop across evaporator coil in the indoor unit is between 20 F to 28 F. 9. Verify that system refrigerant is correct by one of the following methods listed in order of preference by Spacepak. A. Check the super heat leaving the evaporator coil against the corresponding suction pressure from the schrader fitting at the fan coil unit which can be accessed through the service panel. Superheat value should be between 9 and 12 F. B. If a sight glass has been installed on the liquid line at the air handler check for the presence of flashing. CHARGING COOLING ONLY SYSTEMS After start-up, allow the system to operate for approximately 30 minutes in order to establish stable operating conditions. Check that the temperature drop across the evaporator coil is 20 F to 30 F. Do not attempt to adjust the charge at ambient temperatures below 65 F. 1. Check refrigerant charge is correct by checking the super heat leaving the evaporator coil against the corresponding suction pressure from the schrader fiting at the fan coil unit, which can be accessed through the service panel. Superheat value should be between 9 and 12 F. If a sight glass has been installed on the liquid line at the air handler check for the presence of flashing. 2. Determine superheat from Figure If the superheat is too high, add refrigerant gas to the suction line service port. Watch pressure gauge and thermometer for correct superheat. 17

18 NOTE: Do not introduce refrigerant liquid to system through suction port. Liquid in the suction line may damage the compressor. 4. If superheat is too low, slowly bleed refrigerant from suction line service port into an appropriate refrigerant recovery device. Watch pressure gauge and thermometer for correct superheat. CAUTION: Releasing refrigerant gas into the atmosphere is a criminal offense. It is important that the system be properly charged to avoid an overcharged system, but also to ensure that the system operates as efficiently as possible and delivers full capacity. SECTION 4: MAINTENANCE The Space-Pak system has been designed to provide years of trouble-free performance in normal installations. Examination by the homeowner at the beginning of each cooling season, and in mid-season should assure continued, good performance. In addition, the system should be examined by a qualified service professional at least once every year. BEFORE EACH COOLING SEASON 1. Check and clean air filter. The air filter is permanent type. Remove and clean thoroughly with soap solution and water. 2. Check fan coil unit. Turn off unit power disconnect switch and remove service access panels. a. Inspect evaporator coil and blower wheel for buildup of dust and dirt. Clean with solvent and/ or water as necessary. 3. Check that unit condensate drain is clear and free running, and plug is in cleanout. 4. For outdoor condensing unit, follow manufacturer s maintenance instructions. 5. Follow System Start-Up & Adjustments procedures in Section 3 of this manual. IF SYSTEM FAILS TO OPERATE 1. Check that thermostat switch is set for proper mode of operation and is set below room temperature. 2. Check that outdoor unit is operating. 3. Check for tripped circuit breaker or blown fuse at either the main fuse box or at unit disconnect box on or near the condensing unit. Replace blown fuse with same size and type. b. Replace service access panels and turn on unit power disconnect switch. Measured Corresponding Superheat Values (F) Suction Saturation Pressure (PSIG) Temperature (F) Measured Suction Line Temperatures (F) FIGURE 3.1: R-22 SUPERHEAT TABLE 18

19 REF. NAME OF PART PART NO. ESP-2430D ESP-3642D ESP-4860D NO. 1 Anti-Frost Control BM Drain Pan Assembly BM Drain Pan Assembly BM Drain Pan Assembly BM Coil Assembly BM Coil Assembly BM Coil Assembly BM Expansion Valve Expansion Valve Expansion Valve Transformer BM Motor Motor Motor Blower Wheel Blower Wheel Plenum Ring Assembly BM Terminal Block (L.V.) Terminal Block (H.V.) Access Panel BM Fan Relay Float Switch (Optional) BM L1 L FIGURE 4.1: MODEL ESP-D GENERAL ASSEMBLY 19

20 LIMITED WARRANTY Central Air Conditioning Products The Manufacturer warrants to the original owner at the original installation site that the Central Air Conditioning Products (the Product ) will be free from defects in material or workmanship for a period not to exceed one (1) year from the startup or eighteen (18) months from date of shipment from the factory, whichever occurs first. If upon examination by the Manufacturer the Product is shown to have a defect in material or workmanship during the warranty period, the Manufacturer will repair or replace, at its option, that part of the Product which is shown to be defective. This limited warranty does not apply: a) if the Product has been subjected to misuse or neglect, has been accidentally or intentionally damaged, has not been installed, maintained or operated in accordance with the furnished written instructions, or has been altered or modified in any way. b) to any expenses, including labor or material, incurred during removal or reinstallation of the defective Product or parts thereof. c) to any workmanship of the installer of the Product. This limited warranty is conditional upon: a) shipment, to the Manufacturer, of that part of the Product thought to be defective. Goods can only be returned with prior written approval from the Manufacturer. All returns must be freight prepaid. b) determination, in the reasonable opinion of the Manufacturer, that there exists a defect in material or workmanship. Repair or replacement of any part under this Limited Warranty shall not extend the duration of the warranty with respect to such repaired or replaced part beyond the stated warranty period. THIS LIMITED WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES, EITHER EXPRESS OR IMPLIED, AND ALL SUCH OTHER WARRANTIES, INCLUDING WITHOUT LIMITATION IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, ARE HEREBY DISCLAIMED AND EXCLUDED FROM THIS LIMITED WARRANTY. IN NO EVENT SHALL THE MANUFACTURER BE LIABLE IN ANY WAY FOR ANY CONSEQUENTIAL, SPECIAL, OR INCIDENTAL DAMAGES OF ANY NATURE WHATSOEVER, OR FOR ANY AMOUNTS IN EXCESS OF THE SELLING PRICE OF THE PRODUCT OR ANY PARTS THEREOF FOUND TO BE DEFECTIVE. THIS LIMITED WARRANTY GIVES THE ORIGINAL OWNER OF THE PRODUCT SPECIFIC LEGAL RIGHTS. YOU MAY ALSO HAVE OTHER RIGHTS WHICH MAY VARY BY EACH JURISDICTION.